水润滑条件下转速对车轮钢滚动接触疲劳和磨损性能的影响

为探究水润滑条件下转速对车轮钢滚动接触疲劳和磨损性能的影响,利用滚动接触摩擦磨损试验测试不同转速下车轮试样的剥离寿命、摩擦因数和磨损率,并结合磨损形貌和裂纹扩展形貌观察,对比分析不同转速下摩擦磨损和剥离寿命的影响因素。结果表明:随转速提高,车轮材料氧化程度加剧,导致摩擦因数逐渐增加;当转速由250 r/min增至500 r/min时,摩擦因数增幅较小,应变速率增加导致磨损率下降,当转速由500 r/min增至1000 r/min时,摩擦因数急剧增加,导致材料磨损率增加;随转速提高,剖面塑性流动层厚度、裂纹扩展角度、裂纹分叉深度和最大扩展深度均呈现减小趋势。转速增加带来的摩擦因数的增加,一方面缩短裂纹萌生寿命,另一方面减小了裂纹发生向上转折的深度,最终导致滚动接触疲劳寿命随转速的增加而减小。     

滚动接触疲劳短裂纹扩展机制及预防研究

采用有限元分析软件ANSYS,在无摩擦、纯滚动、全滑动三种运行状态下,研究钢轨表面短裂纹的疲劳断裂机制,并分析轮轨间摩擦因数对接触疲劳裂纹扩展速率的影响。结果表明,轮轨接触的疲劳裂纹为张开型和滑开型同时存在的复合型裂纹,裂纹发生张开型破坏的最危险位置在接触斑边缘的位置;随着裂纹角度的增加,应力强度因子KI增加而KII减小,其中60°裂纹的扩展速率最快;摩擦力的存在明显加剧了裂纹扩展速率,且随着摩擦因数的增加而增大。对钢轨表面预防性打磨周期进行预测时,以60°裂纹为基准的预测结果偏安全。     

非共线复合型裂纹扩展特性分析

以带多点损伤的空孔板为研究对象,利用数值分析法分析裂纹起裂位置和裂纹倾斜角对应力强度因子的影响,对比了共线多裂纹与非共线复合型裂纹起始扩展速率和扩展寿命的差异。结果表明:非共线复合型裂纹起始扩展速率偏大,裂纹扩展寿命缩短约2.5%。在非共线复合型裂纹模型中,随着裂纹倾斜角增加,等效应力强度因子先增大后减小,且在15°时,整体裂纹扩展速率达最大值。相邻孔间裂纹的相对位置和相对方位影响裂纹的扩展路径,进而影响裂纹扩展寿命。     

钢轨踏面斜裂纹模拟再现试验研究

根据钢轨踏面斜裂纹的损伤特点和轮轨力与斜裂纹关系分析设计试验方案,在西南交通大学JD-1轮轨模拟试验机上,对广深高速铁路铺设的PD3热轧钢轨材料进行了斜裂纹损伤再现试验。试验结果表明,轮轨接触方式是钢轨斜裂纹产生和扩展的重要影响因素;轴重增加会增大轮轨接触应力,增加磨损量,加速接触疲劳现象的产生。     

磨损对钢轨滚动接触疲劳损伤的影响

通过对广深铁路钢轨疲劳斜裂纹与钢轨侧磨的现场调查及钢轨滚动疲劳模拟试验,研究了钢轨滚动接触疲劳损伤与磨损之间的作用关系,分析了轮、轨滚动疲劳过程中钢轨磨损率对疲劳裂纹形成及裂纹扩展寿命的影响。结果表明:钢轨磨损严重时,疲劳斜裂纹损伤就表现轻微,钢轨滚动疲劳损伤与磨损之间表现为相互竞争与制约的耦合作用关系;通过增加磨损率能减轻钢轨的滚动疲劳损伤,有利于延长钢轨的疲劳裂纹扩展寿命。     

38CrSi自配副的摩擦磨损性能

采用自制的销盘式摩擦磨损试验机研究了38CrSi自配副干滑动时的摩擦因数、磨损率随滑动速度和载荷的变化规律;利用SEM观察了磨损面的微观形貌,分析了摩擦磨损机理。结果表明:其摩擦因数随着载荷和速度的增加而减小;磨损率随着载荷的增加而增大,随着速度的增加先增大后减小,和常用材料的磨损率随速度增加而增大的规律不同;磨损机理为磨粒磨损和粘着磨损。     

38CrSi自配副的摩擦磨损性能

采用自制的销盘式摩擦磨损试验机研究了38CrSi自配副干滑动时的摩擦因数、磨损率随滑动速度和载荷的变化规律;利用SEM观察了磨损面的微观形貌,分析了摩擦磨损机理。结果表明：其摩擦因数随着载荷和速度的增加而减小;磨损率随着载荷的增加而增大,随着速度的增加先增大后减小,和常用材料的磨损率随速度增加而增大的规律不同;磨损机理为磨粒磨损和粘着磨损。     

响应曲面法优化封隔器胶筒密封性能参数的研究

利用有限元分析软件建立某压缩式封隔器胶筒的二维模型,分析53.85 MPa轴向载荷作用下,胶筒的端面倾斜角、胶筒子厚度、筒高和摩擦因数对胶筒与套管之间最大接触应力的影响。结果表明:最大接触应力随端面角的增加呈W形分布,随子厚度的增加先增大后减小最后趋于稳定,随胶筒筒高的的增大而减小,随摩擦因数的增大先缓慢减小后急剧增大;端面角为45°,胶筒子厚度取9 mm,筒高介于80～120 mm,摩擦因数在0.1～0.3范围内时,研究的封隔器的胶筒与套管之间最大接触应力较高,胶筒的密封性能较好。基于有限元分析结果,设计响应曲面法实验,研究多因子不同水平下胶筒最大接触压力响应的变化情况。结果表明:对最大接触应力影响最大的因子是摩擦因数,最小的是筒高,交互项端面倾斜角和筒高、端面倾斜角和摩擦因数、胶筒子厚度和擦因数、筒高和摩擦因数对响应具有显著性影响;胶筒密封性能最佳的因子组合方案为端面倾斜角为48.2°、子厚度为9 mm、筒高为90 mm、摩擦因数为0.1。     

磁场条件下钢轨材料的摩擦磨损性能试验研究

基于HSR-2M高速往复摩擦磨损试验机,试验研究在永磁体磁场条件下,法向载荷、往复速度等参数对钢轨材料摩擦性能的影响,通过磨痕形貌分析其磨损机制,并与无磁场条件下的结果进行对比。试验结果表明:磁场的引入可以在一定程度上减小钢轨材料的摩擦因数、磨损率;增大滑动速度对摩擦因数和磨损率均有减小作用,增大载荷能够降低摩擦因数,但磨损率增加;磁场能够提高钢轨材料在摩擦过程中的磨损性能。无磁场时,钢轨材料磨损形式为典型的磨粒磨损,摩擦系统的磨损率和摩擦因数较大;有磁场时,磨损形式主要为黏着磨损,摩擦因数和磨损率较小。     

基于热力耦合的钢轨接触疲劳裂纹扩展特性分析

采用热弹塑性有限元法和裂纹尖端位移法,对轮轨全滑接触状态下的钢轨表面斜裂纹的扩展特性进行分析.热力耦合有限元模型中,考虑轮轨自由表面与环境热对流、裂纹表面间热传导和温度对材料参数的影响,通过移动边界条件模拟轮轨接触区的移动,计算轮轨摩擦因数、裂纹表面间的摩擦因数和裂纹角度对钢轨表面裂纹扩展特性的影响.计算结果表明:在热...     

水介质下打磨磨痕对钢轨疲劳损伤的影响

采用棕刚玉砂纸在钢轨试样表面处理得到不同角度打磨磨痕,利用MMS-2A轮轨摩擦磨损试验机研究了水介质下不同角度打磨磨痕对钢轨疲劳裂纹扩展的影响。结果表明：水介质条件下打磨磨痕与运行方向夹角在0°～45°范围内时,钢轨表面粗糙度略高,高于夹角为70°、90°打磨磨痕区域表面粗糙度;相比没有打磨磨痕的光滑区域,0°～45°打磨磨痕将加速钢轨接触疲劳裂纹的扩展,20°磨痕区域的裂纹扩展尤为严重,出现了许多分支裂纹;而70°、90°的打磨磨痕一定程度上会减缓疲劳裂纹的生长,90°打磨磨痕区域基本只存在表层裂纹;打磨磨痕角度由0°向90°增大时,裂纹扩展深度先变大后变小,而裂纹扩展角度呈现出逐渐减小的趋势。     

PD3与U71Mn钢轨疲劳裂纹扩展特性研究

针对广深线铺设使用中已出现斜线状裂纹的PD3和U71Mn两种钢轨试样进行了成分、机械性能与微观形貌分析。结果表明：PD3钢轨的强度性能优于U71Mn钢轨的强度性能;U71Mn钢轨裂纹扩展角度比PD3钢轨的裂纹扩展角度要小;U71Mn钢轨在疲劳裂纹扩展中以沿晶和穿晶混合型扩展为主;而PD3钢轨试样的疲劳裂纹扩展主要以穿晶为主,裂纹更容易扩展,扩展速率更大。综合分析表明,U71Mn钢轨更适合于高速铁路铺设使用。     

Wear of copper-based solid solutions

The effect of solute atoms on sliding wear was studied by alloying OFHC copper with chromium, silicon and tin. The hardness was found to increase linearly with the atomic solute content although the rate of hardening was different for different solutes.Microscope observations show that the principal mode of wear is indeed delamination. The results further show that both the wear rate and the friction coefficient are reduced when the solute content is increased. The reduction in the friction coefficient is a consequence of reduced plowing contribution to the tangential component of the surface traction. Both the increase in hardness and the decrease in the friction coefficient reduce the wear since both affect the subsurface deformation rate and consequently the crack nucleation rate. The lower coefficient of friction also reduces the crack propagation rate and the thickness of the wear sheets.     

低温下高速车轮材料滚动磨损与疲劳损伤行为

利用低温环境轮轨磨损模拟试验装置,研究了高速铁路车轮材料在室温及低温环境下的滚动接触疲劳损伤行为。结果表明：低湿度的低温环境导致车轮材料磨损率、塑性变形及疲劳损伤较室温下明显加重。随试验温度的降低,轮轨摩擦因数、磨损率及表面硬度均呈现先急剧上升后轻微下降趋势。室温工况下磨痕表面有严重的犁沟现象,而低温工况下车轮试样表面以疲劳裂纹及剥落损伤为主。随着温度的降低,磨损形式由氧化磨损、磨粒磨损逐渐向疲劳及粘着磨损转变。车轮材料裂纹主要沿较软的铁素体线扩展,室温下剖面损伤较轻微。低温工况下由于车轮材料发生脆化,珠光体呈现不同于室温下的形貌及分布特性。在低温下,表层裂纹扩展角度及次表层裂纹长度增加,同时表层裂纹易于汇合并产生分支。     

非对称楔形压头印压玻璃裂纹产生与扩展规律的研究

研究了非对称楔形压头印压玻璃时裂纹的产生及扩展规律。根据非对称楔印压玻璃时典型的裂纹照片 ,可明显看出存在加载裂纹、横向裂纹和表面下裂纹 ,并且都偏离印压表面法线方向。试验表明 :加载裂纹的偏角αc 与楔角对称线偏角αa 总是符号相同 ;对于形状相似的压头 ,楔角对称线偏角越大 ,裂纹偏角也越大 ;对双斜压头而言 ,如果楔角不等 ,但楔角对称线偏角相等 ,裂纹偏角仍大致相等。     

钢丝微动疲劳裂纹萌生寿命预测研究*

钢丝微动疲劳过程中,钢丝裂纹萌生特性直接影响其裂纹扩展特性,进而制约钢丝微动疲劳寿命,因此开展钢丝微动疲劳裂纹萌生寿命预测研究具有重要意义。基于有限元法、摩擦学理论和断裂力学理论,运用Smith-Watson-Topper（SWT）多轴疲劳寿命准则建立考虑磨损的钢丝微动疲劳裂纹萌生寿命预测模型,基于多种不同的钢丝疲劳参数估算方法对钢丝的微动疲劳裂纹萌生寿命进行了预测,并探究接触载荷、疲劳载荷、交叉角度及钢丝直径等微动疲劳参数对钢丝微动疲劳裂纹萌生寿命的影响规律。结果表明：基于中值法的预测结果最接近实际值;在微动疲劳过程中,钢丝微动疲劳裂纹萌生寿命主要与接触载荷和疲劳载荷相关。通过引入微动损伤参数建立简化的适用于钢丝绳的钢丝微动疲劳裂纹萌生寿命预测模型,通过与考虑磨损的预测模型计算结果进行对比验证了该模型的准确性。     

Mechanics of crack propagation in delamination wear

A mathematical model of subsurface crack propagation in sliding contact is developed. It is shown that linear elastic fracture mechanics may be applied to such problems, even for elastoplastic solids. An equation to predict wear rates is derived, which should apply in delamination wear to materials in which crack nucleation is easy. Results of calculations of stress intensity factors for various subsurface cracks and coefficients of friction are presented. The numerical calculations were done only for coefficients of friction greater than 0.5.The calculations show that there is a characteristic crack propagation depth below the surface, which increases with increasing coefficient of friction. In addition, the change in stress intensity factor and hence the crack propagation rate, increases with increasing coefficient of friction. A comparison between these calculations and approximate crack growth rates in sliding wear shows that the results agree reasonably well.The model is used to explain the phenomenon that increased hardness sometimes increases wear. A possible explanation for seizure in geometrically constrained systems is advanced. The model may be used to predict wear rates from first principles in the near future.     

Wear of two-phase metals

The effect of the second-phase particle structure on the wear properties of two-phase metals was investigated by using precipitation-hardened copperchromium alloys (Cu-0.58 at.% Cr and Cu-0.81 at.% Cr) aged for different periods of time at 500 °C. The hardness of these materials was found to increase initially with the aging time and then to decrease; the maximum value was reached after about 100 min of aging. Metallographic examination of worn specimens indicated that the wear process proceeded by subsurface deformation, crack nucleation and crack propagation, i.e. by delamination. The friction coefficient was found to be constant for both alloys and for all aging times. In the early stages of precipitation both the wear rate and the wear coefficient decreased. As the aging continued the wear rate and the wear coefficient increased even though the hardness also increased. The wear coefficient remained constant for the overaged alloys. The decrease in both the wear rate and wear coefficient in the early stages of precipitation is due to the fact that particles are small and coherent and require a large amount of subsurface deformation for crack nucleation. With further aging, the particles grow and become incoherent, increasing the wear rate due to easier crack nucleation. For the case of the overaged alloys, the wear coefficient tends to become constant because the wear process is controlled by the crack propagation rate which is found to be independent of the aging time for both alloys.